A logic conditioning system for easy-clean coating preparation process

Abstract

The present application relates to the technical fields of precision preparation automation control, and discloses a logic adjustment system for easy-to-clean coating preparation process, comprising: a load identification unit for monitoring driving source electric parameters and extracting dynamic load parameters; a working condition prediction unit for determining coating liquid viscoelastic evolution characteristics according to the parameter instantaneous slope; a time delay decoupling unit for calculating physical response time delay amount based on the evolution characteristics; a compensation synthesis unit for superimposing phase cancellation components in the original instruction to synthesize calibration instructions; and a closed-loop control unit for adjusting output frequency according to the calibration instructions to maintain coating thickness consistency. The present application establishes a prediction compensation mechanism by using the endogenous load characteristics of the driving mechanism, overcomes the space-time phase misplacement of non-Newtonian fluid transmission process, realizes the advanced coverage of the fluid response lag in the adjustment action timing, effectively suppresses system oscillation and improves the steady-state precision of coating preparation.

Description

Technical Field

[0001] This invention belongs to the field of precision manufacturing automation control technology, and particularly relates to a logic adjustment system for easy-clean coating preparation process. Background Technology

[0002] Currently, continuous production processes for easy-clean coatings typically employ closed-loop control systems using proportional-integral-derivative (PID) algorithms. These systems collect material state deviation information via pressure sensors and flow meters located at the end of the delivery pipeline or downstream of the coating head, and adjust the output frequency of the drive pump motor accordingly to maintain uniform coating thickness. However, as manufacturing processes evolve towards higher linear velocities, the obvious shear-thinning characteristics and viscoelastic response hysteresis of the easy-clean coating liquid pose significant challenges to the control mechanism. The physical momentum lag during fluid transport in the pipeline means that the signals collected by the control system only represent the process state at past moments. Furthermore, when the control command is applied to the actuator and drives the material to move, the physical state has already undergone nonlinear shifts, causing phase distortion in the control. The industry has attempted to alleviate these delays by adding constant temperature and pressure hardware or increasing the sampling rate. However, hardware increases equipment costs, and increasing the sampling rate cannot overcome the physical spacing generated by the detection path, making it difficult to eliminate the inherent delay of the feedback loop at the logical level.

[0003] Besides improving the external hardware environment, exploring physical intervention methods to directly improve fluid transport characteristics and reduce hysteresis effects has become a direction. For example, Chinese invention patent application CN118788572A discloses a system for using acoustic softening to transport non-Newtonian materials over long distances. It uses acoustic wave generators arranged along the conduit to apply acoustic shearing and agitation to the material to reduce viscosity. This method, which relies on external energy fields to change the physical form of the fluid, is a static improvement. In high-speed dynamic continuous coating, the viscoelastic evolution of the material is instantaneous and coupled with the operating conditions. Physical viscosity reduction methods cannot address the underlying contradiction between the control logic and the phase deviation of the physical response. Introducing an acoustic generator increases system redundancy and maintenance costs. High-frequency vibration lacks logical coordination and is prone to becoming a source of interference, making it difficult to close the steady-state boundary of coating accuracy.

[0004] Therefore, how to utilize the intrinsic electromagnetic characteristics of the drive mechanism to establish a predictive regulation mechanism to offset the nonlinear time delay in the non-Newtonian fluid transmission process and improve the alignment accuracy between the regulation command and the fluid physical state has become the technical problem to be solved by this invention. Summary of the Invention

[0005] The present invention aims to solve the problem of phase misalignment between control commands and physical states caused by the time delay of non-Newtonian fluid transmission.

[0006] In this technical solution, a logic control system for an easy-clean coating preparation process is provided, the system comprising: The load identification unit, which is connected to the flow drive end, is used to monitor the electrical parameters of the pump drive source and extract dynamic load parameters that characterize the electromagnetic torque pulsation rate of the pump drive source, so as to identify the transient electromagnetic characteristic changes generated by the flow drive end when driving non-Newtonian fluid. The working condition prediction unit, which is connected to the load identification unit, is used to determine the viscoelastic evolution characteristics of the coating liquid under the current shear conditions by using the instantaneous slope of the dynamic load parameters in the time domain, so as to capture the damping characteristic shift trend caused by the consistency fluctuation of the coating liquid. The time delay decoupling unit, which is connected to the working condition prediction unit, is used to calculate the adjustment time delay between the command issuance time of the flow drive end and the physical response state of the coating liquid based on the preset fluid dynamics model and the viscoelastic evolution characteristics, so as to quantify the momentum lag of the fluid in the delivery pipeline. The compensation synthesis unit, which is connected to the time delay decoupling unit, is used to superimpose phase cancellation components that are opposite to the adjustment time delay in the original adjustment command stream to synthesize a calibration command with time delay offset characteristics, so that the timing of the adjustment action leads the physical deviation feedback time on the logic axis. The closed-loop control unit, connected to the compensation synthesis unit, is used to adjust the output frequency of the flow drive in real time according to the calibration command, so as to neutralize the command phase distortion induced by the adjustment delay and maintain the consistency of the coating thickness.

[0007] Preferably, the load identification unit is used to perform spectral decomposition on the monitored electrical parameters to extract harmonic current components of a specific order, and correct the confidence level of the dynamic load parameters based on the amplitude fluctuation rate of the harmonic current components, thereby removing high-frequency noise disturbances in the electrical parameters introduced by environmental mechanical vibration.

[0008] Preferably, the compensation synthesis unit includes a time axis calibration module, which is used to acquire the real-time linear velocity of the preparation production line and linearly scale the injection time of the phase cancellation component according to the ratio of the real-time linear velocity to the physical distance from the sensor to the coating point, so as to achieve phase alignment under varying operating conditions.

[0009] Preferably, the closed-loop control unit includes a steady-state holding module, which is used to stop the logical update of the calibration command and lock the current operating frequency of the flow drive when the acquired coating thickness deviation is within the gradient dead zone range of 0.5% to 1.5%, so as to suppress the mechanical chatter of the pump drive source.

[0010] Preferably, the load identification unit is used to collect the steady-state current average value of the pump drive source under the reference operating condition of constant frequency at the flow drive end and use it as a static reference. Then, the static reference is used to normalize the electrical parameters monitored in real time to extract the transient load component.

[0011] Preferably, the system also includes a limiting protection unit, which monitors the output amplitude of the calibration command and, when the output amplitude exceeds the preset safety envelope, performs saturation truncation on the calibration command according to physical limits to prevent the closed-loop system from losing control due to prediction deviation.

[0012] Preferably, the operating condition prediction unit is used to query a preset rheological property mapping library, convert dynamic load parameters into physical scalar indices characterizing the changes in surface tension and consistency of the coating liquid, and use the physical scalar indices as input weight parameters for the compensation synthesis unit to calculate the phase cancellation component.

[0013] Preferably, the compensation synthesis unit is used to continuously record the historical fluctuation trajectory of the adjustment time delay, and when the historical fluctuation trajectory exhibits periodic resonance characteristics, it reduces the proportional gain coefficient of the phase cancellation component to eliminate the risk of pipeline system resonance caused by the viscoelasticity of non-Newtonian fluid.

[0014] Preferably, the system further includes a self-diagnostic unit, which is used to calculate the time-domain residual between the expected physical state corresponding to the calibration command and the actual response state of the coating liquid, and to correct the mapping accuracy of the viscoelastic evolution characteristics in the working condition prediction unit online based on the time-domain residual.

[0015] Compared with existing technologies, the logic control system of this invention for easy-clean coating preparation processes has the following advantages: 1. In the logic regulation of the easy-clean coating preparation process, by extracting the load feature vector of the pumping execution unit, an endogenous feedback path between the regulation command and the fluid rheological state is established. This overcomes the constraint of the physical transmission delay generated by the delivery pipeline on the regulation timeliness. Traditional feedback logic relies on the monitoring data of the end sensor, which leads to a significant lag offset between the regulation action and the actual physical fluctuation of the material. This invention uses the second-order rate of change of the pumping motor current fluctuation to characterize the transient flow resistance evolution of the coating liquid in the pipeline. This allows the regulation system to complete the offset compensation at the logic layer before the physical deviation is transmitted to the coating end, eliminating the absolute dependence of the regulation loop on the downstream detection signal.

[0016] 2. The constructed virtual phase compensation unit achieves precise alignment between the timing of the adjustment command and the fluid response cycle by mapping the load deviation vector ahead of the logical time axis. Since the easy-clean coating has obvious non-Newtonian fluid characteristics, its viscosity exhibits nonlinear drift with shear rate. This invention calculates the physical delay constant and injects a cancellation component into the adjustment command flow, so that the timing of the actuator can cover the momentum hysteresis and viscoelastic hysteresis cycle of the fluid, ensuring that the adjustment system maintains the dynamic response characteristics of zero phase difference under high-frequency disturbances.

[0017] 3. By introducing a linear velocity compensation unit and a time axis calibration branch, the system establishes a dynamic adaptive capability of the regulation logic to changes in the production process window. When the production line performs acceleration or deceleration, the system collects linear velocity data in real time and scales the offset of the virtual phase. Combined with the end pressure characteristics, the system corrects the delay constant online. This multi-mechanism synergistic coupling logic solves the problem that a single prediction model is prone to failure under varying operating conditions. It ensures that the regulation system still has a definite stability boundary in complex industrial environments and avoids the risk of systemic oscillation caused by nonlinear fluctuations of fluid. Attached Figure Description

[0018] Figure 1 This is the dynamic compensation logic and signal flow diagram of the logic adjustment system of the present invention; Figure 2 This is a connection diagram of the functional modules of the present invention, including self-diagnosis and amplitude limiting protection. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0020] It should be noted that all directional and positional terms used in this invention, such as: up, down, left, right, front, back, vertical, horizontal, inner, outer, top, bottom, transverse, longitudinal, center, etc., are only used to explain the relative positional relationship and connection between components in a specific state (as shown in the accompanying drawings). They are only for the convenience of describing this invention and do not require that this invention be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention. In addition, the descriptions of "first," "second," etc., in this invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated.

[0021] In the description of this invention, unless otherwise explicitly specified and limited, the terms installation, connection, and linking should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections; they can refer to direct connections or indirect connections through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0022] In the description of this specification, references to the terms "an embodiment," "some embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example, and the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0023] A logic control system for an easy-clean coating preparation process, the system comprising: The load identification unit, which is connected to the flow drive end, is used to monitor the electrical parameters of the pump drive source and extract dynamic load parameters that characterize the electromagnetic torque pulsation rate of the pump drive source, so as to identify the transient electromagnetic characteristic changes generated by the flow drive end when driving non-Newtonian fluid. The working condition prediction unit, which is connected to the load identification unit, is used to determine the viscoelastic evolution characteristics of the coating liquid under the current shear conditions by using the instantaneous slope of the dynamic load parameters in the time domain, so as to capture the damping characteristic shift trend caused by the consistency fluctuation of the coating liquid. The time delay decoupling unit, which is connected to the working condition prediction unit, is used to calculate the adjustment time delay between the command issuance time of the flow drive end and the physical response state of the coating liquid based on the preset fluid dynamics model and the viscoelastic evolution characteristics, so as to quantify the momentum lag of the fluid in the delivery pipeline. The compensation synthesis unit, which is connected to the time delay decoupling unit, is used to superimpose phase cancellation components that are opposite to the adjustment time delay in the original adjustment command stream to synthesize a calibration command with time delay offset characteristics, so that the timing of the adjustment action leads the physical deviation feedback time on the logic axis. The closed-loop control unit, connected to the compensation synthesis unit, is used to adjust the output frequency of the flow drive in real time according to the calibration command, so as to neutralize the command phase distortion induced by the adjustment delay and maintain the consistency of the coating thickness.

[0024] Preferably, the load identification unit is used to perform spectral decomposition on the monitored electrical parameters to extract harmonic current components of a specific order, and correct the confidence level of the dynamic load parameters based on the amplitude fluctuation rate of the harmonic current components, thereby removing high-frequency noise disturbances in the electrical parameters introduced by environmental mechanical vibration.

[0025] Preferably, the compensation synthesis unit includes a time axis calibration module, which is used to acquire the real-time linear velocity of the preparation production line and linearly scale the injection time of the phase cancellation component according to the ratio of the real-time linear velocity to the physical distance from the sensor to the coating point, so as to achieve phase alignment under varying operating conditions.

[0026] Preferably, the closed-loop control unit includes a steady-state holding module, which is used to stop the logical update of the calibration command and lock the current operating frequency of the flow drive when the acquired coating thickness deviation is within the gradient dead zone range of 0.5% to 1.5%, so as to suppress the mechanical chatter of the pump drive source.

[0027] Preferably, the load identification unit is used to collect the steady-state current average value of the pump drive source under the reference operating condition of constant frequency at the flow drive end and use it as a static reference. Then, the static reference is used to normalize the electrical parameters monitored in real time to extract the transient load component.

[0028] Preferably, the system also includes a limiting protection unit, which monitors the output amplitude of the calibration command and, when the output amplitude exceeds the preset safety envelope, performs saturation truncation on the calibration command according to physical limits to prevent the closed-loop system from losing control due to prediction deviation.

[0029] Preferably, the operating condition prediction unit is used to query a preset rheological property mapping library, convert dynamic load parameters into physical scalar indices characterizing the changes in surface tension and consistency of the coating liquid, and use the physical scalar indices as input weight parameters for the compensation synthesis unit to calculate the phase cancellation component.

[0030] Preferably, the compensation synthesis unit is used to continuously record the historical fluctuation trajectory of the adjustment time delay, and when the historical fluctuation trajectory exhibits periodic resonance characteristics, it reduces the proportional gain coefficient of the phase cancellation component to eliminate the risk of pipeline system resonance caused by the viscoelasticity of non-Newtonian fluid.

[0031] Preferably, the system further includes a self-diagnostic unit, which is used to calculate the time-domain residual between the expected physical state corresponding to the calibration command and the actual response state of the coating liquid, and to correct the mapping accuracy of the viscoelastic evolution characteristics in the working condition prediction unit online based on the time-domain residual.

[0032] Example 1: In a continuous roll-to-roll coating production line scenario for superhydrophobic and easy-clean coatings, the production line speed is in the range of 60m / min to 80m / min. At this speed, the coating liquid exhibits shear-thinning non-Newtonian fluid characteristics, and the length of its conveying pipeline is in the range of 5m to 8m. When the proportional-integral-derivative (PID) control logic based on the end pressure signal or thickness feedback detects a material flow deviation, the control phase distortion is caused by fluid momentum hysteresis and viscoelastic response delay. When the control command is applied to the actuator and drives the material to generate displacement, its physical state has already undergone nonlinear shift. This causes the control loop to be unable to compensate for the rheological delay in time, resulting in systemic overshoot or control oscillation. Ultimately, this leads to the standard deviation of the coating thickness being at the level of 0.25μm.

[0033] The load identification unit is connected to the flow drive end to monitor the electrical parameters of the pump drive source and extract dynamic load parameters characterizing the electromagnetic torque pulsation rate of the pump drive source. This identifies transient electromagnetic characteristic changes generated by the flow drive end when driving non-Newtonian fluids. The operating condition prediction unit uses the instantaneous slope of this dynamic load parameter in the time domain to determine the viscoelastic evolution characteristics of the coating liquid under the current shear conditions, in order to capture the damping characteristic shift trend caused by coating liquid consistency fluctuations. This step correlates the impedance characteristics of the drive unit to the logic loop in real time, enabling the system to obtain in-situ sensing before physical deviations are transmitted to the coating end. This solves the constraint on adjustment timeliness caused by the physical transmission delay generated by the delivery pipeline. In this sensing stage, although the change in the surface tension of the coating liquid occurs at the microscale of the coating head interface, the resulting meniscus of the coating lip... The contraction and expansion of the surface topography instantly alters the macroscopic back pressure of the fluid at the system's end. Due to the extremely low compressibility of the coating liquid within the fully enclosed delivery pipeline, the sudden pressure change at this end micro-interface is transmitted instantaneously in the form of a mechanical pressure wave, according to the fluid's sound velocity, to the pump outlet at the flow-driven end. This causes the pump rotor to face a sudden hydraulic impedance transition. This physical-scale fluid dynamic coupling effect transforms the nonlinear evolution of the end interface tension into the electromagnetic torque increment required for the pump motor rotor to overcome additional liquid resistance in real time. This establishes the physical feasibility of the system being able to reversely calculate the drift of the material's micro-surface tension simply by monitoring the transient fluctuation characteristics of the stator current. The time-delay decoupling unit calculates the adjustment time delay between the command issuance time at the flow-driven end and the physical response state of the coating liquid based on the preset fluid dynamics model and viscoelastic evolution characteristics. To quantify the momentum lag of the fluid in the delivery pipeline, the compensation unit superimposes and adjusts the adjustment delay in the original adjustment command flow. The phase-cancelling components, which are opposite to each other, are used to synthesize a calibration command with time-delay offset characteristics, so that the timing of the adjustment action is advanced on the logical axis before the feedback time of the physical deviation. Generate according to the following logical relationship: ,in, For calibration instructions, For proportional gain, The integral time constant is... The prediction bias after mapping to the virtual phase, To adjust the delay.

[0034] The closed-loop control unit adjusts the output frequency of the flow drive in real time according to the calibration command, and coordinates with the real-time linear velocity of the production line obtained by the time axis calibration module to linearly scale the injection time of the phase cancellation component to achieve phase alignment under varying operating conditions. When the obtained coating thickness deviation is within the gradient dead zone range of 0.5% to 1.5%, the steady-state holding module stops updating the logic of the calibration command and locks the current operating frequency of the flow drive to suppress the mechanical chatter of the pump drive source. Ultimately, under the condition that the material viscosity fluctuates by 20%, the coating amount fluctuation is controlled within 1.2%, and the standard deviation of the coating thickness control is reduced from 0.25μm to 0.08μm. The adjustment system transforms the rheological law of the material into an adjustment strategy by exploring the load characteristics of the drive pump actuator itself. By presetting the phase advance amount at the command end to offset the nonlinear time delay in the non-Newtonian fluid transmission process, the adjustment action sequence is pre-covered for the fluid response lag, eliminating the systemic oscillation caused by the phase misalignment between the adjustment command and the physical state.

[0035] Example 2: To verify the steady-state accuracy of non-Newtonian fluid easy-clean coatings during high-speed coating, a precision roll-to-roll coating test bench was used as the testing environment. The data source was acquired from an industrial fieldbus interface integrated into the pump actuator drive, outputting a current vector signal with a resolution of 0.01A. The sampling period was... The setting depends on the matching relationship between the electromagnetic torque pulsation frequency of the pump drive source and the logic main frequency of the control unit. In order to balance the real-time performance of the adjustment command and the data processing load, when the main peak of the monitored torque pulsation spectrum is below 100Hz, the sampling period is determined according to the sampling theorem. The value tends to the lower limit of 5ms to prevent signal aliasing and maintain the accuracy of time delay calculation. At the same time, random noise with a signal-to-noise ratio of 20dB is actively superimposed in the acquisition link, and power frequency interference with a frequency of 50Hz is simulated.

[0036] The test setup included a production line speed of 70 m / min, a conveying pipeline length of 6 m, and an initial coating liquid viscosity of 1200 mPa·s. In the control group, the shielded delay decoupling unit and the compensation synthesis unit, using a proportional-integral-derivative (PID) adjustment method based on end-deviation feedback, observed that the original current signal exhibited a 12.4 A amplitude impact when the viscosity experienced a 15% step fluctuation. Because this adjustment method could not identify fluid transmission delay, its output frequency command had a 110.5 ms phase deviation from the physical state of the material reaching the coating head, causing coating thickness fluctuations. The measured thickness standard deviation was 0.26 μm, and the system generated adjustment oscillations. In the test group using the logic adjustment system claimed in this invention, the load identification unit extracted dynamic load parameters from the disturbed current signal, with a harmonic fluctuation rate of 3.8%. The operating condition prediction unit captured the instantaneous slope of the dynamic load parameters as 8.6 A / s and mapped it to obtain the equivalent damping coefficient of the coating liquid as key intermediate data. The delay decoupling unit calculated the current adjustment delay based on the fluid dynamics model. The time is 82.4 ms, based on which the compensation synthesis unit generates a phase-precessing calibration command. By superimposing the reverse phase cancellation component, the timing of the adjustment action is advanced on the logic axis before the time when the flow deviation reaches the coating end. The measured data shows that after phase compensation, the coating thickness deviation converges to 0.08μm.

[0037] To verify the rationality of the parameter boundaries, an out-of-range control group was established. When the length of the delivery pipeline increased to 10m and exceeded the upper limit of 8m, the fluid momentum hysteresis exhibited a nonlinear increase. The calculated adjustment time delay was then calculated. The maximum value of the phase shift window preset by the compensation synthesis unit was exceeded, the guiding phase alignment failed, and the thickness deviation increased to 0.22 μm, showing performance degradation. At the same time, when the viscosity of the coating liquid was adjusted to 2500 mPa·s and exceeded the upper limit of the defined range, the flow limiting protection of the pump drive source was triggered due to the fluid shear thickening effect. The dynamic load parameter extracted by the load identification unit became saturated, and its growth rate tended to level off. This indicates that the viscoelastic sensing capability of the system has reached the physical limit, and increasing the viscosity cannot obtain effective time delay compensation gain. The above experimental process confirms that by mining the electromagnetic load characteristics of the drive end and performing phase offset compensation, the physical time delay of non-Newtonian fluid in the transportation process can be effectively offset. The system dynamically matches the adjustment sequence with the fluid physical response cycle and changes the response mode of the adjustment loop to time domain disturbances. This technical route based on logic layer phase reconstruction enables the preparation system to maintain the coating accuracy at the sub-micron level while maintaining high-speed continuous operation, eliminating the risk of process consistency caused by adjustment phase distortion.

[0038] Example 3: This example combines Figures 1 to 2A description of a logic control system for an easy-clean coating preparation process, such as... Figure 1 As shown, the flow drive end includes a pump drive source to respond to closed-loop control actions and output electrical parameters to the load identification unit. The load identification unit monitors the electrical parameters to extract dynamic load parameters, thereby identifying transient electromagnetic characteristic changes, and outputs the dynamic load parameters to the operating condition prediction unit. The operating condition prediction unit determines the viscoelastic evolution characteristics through the instantaneous slope to capture the damping characteristic offset trend, and outputs the viscoelastic evolution characteristics to the time delay decoupling unit. The time delay decoupling unit calculates and adjusts the time delay amount to quantify the momentum lag of the fluid in the delivery pipeline, and outputs the adjusted time delay amount to the compensation synthesis unit. The compensation synthesis unit superimposes the phase cancellation component to synthesize a calibration command with time delay offset characteristics, and outputs the calibration command to the closed-loop control unit. The closed-loop control unit adjusts the output frequency according to the calibration command to neutralize the command phase distortion and maintain the consistency of the coating thickness, and feeds back the output frequency to the aforementioned flow drive end; as Figure 2 As shown, the flow driver in the system is connected in sequence to the load identification unit, the operating condition prediction unit, the delay decoupling unit, the compensation and synthesis unit, and the closed-loop control unit. The closed-loop control unit is connected back to the flow driver. Meanwhile, the compensation and synthesis unit is connected to the self-diagnosis unit and the limiting protection unit, respectively. The self-diagnosis unit is connected back to the operating condition prediction unit, and the limiting protection unit is connected back to the compensation and synthesis unit.

[0039] Example 4: In the online preparation scenario of high-solids-content easy-clean ceramic coatings, the solids content of the coating liquid fluctuates within the range of 30% to 45%, causing a nonlinear shift in the yield stress of the fluid in the delivery pipeline. When the regulating system detects a step change in the electromagnetic torque pulsation rate at the flow drive end due to solid phase agglomeration, the lack of a quantitative discrimination path for the abrupt change in fluid rheology leads to a delay in the calculation of the regulating loop. The inability to accurately align with the true phase of the physical deviation causes a misalignment of more than 30ms between the injection time of the phase compensation component and the actual time when the fluid arrives at the coating head, resulting in local thickening or missed coating. Furthermore, the fixed dead zone setting cannot balance the adjustment sensitivity and the stability of the mechanical mechanism under different shear rates.

[0040] The load identification unit performs discrete sampling of the stator current vector of the monitored pumping drive source, with the sampling frequency set to 10kHz. Using a discrete Fourier transform algorithm with a sliding window length of 1024 sampling points, it extracts the 6th and 12th order harmonic current components from the current spectrum. Based on the electromagnetic induction principle of a three-phase AC motor, the specific harmonics of the stator current directly reflect the periodic mechanical resistance fluctuations of the rotor. In this embodiment, the pumping drive source uses a permanent magnet synchronous servo motor with 3 pole pairs and 12 rotor teeth. The load identification unit acquires the real-time pulse width modulation control signal from the inverter, synchronously captures the three-phase stator current, and sets the sampling frequency to 10kHz. The frequency coverage is at least 40 times the bandwidth of the reference current frequency at the rated speed of the motor to satisfy the Nyquist sampling theorem. The 6th harmonic component is extracted to reflect the basic mechanical vibration parameters introduced by rotor asymmetry. The 12th harmonic component corresponds to the parameters of cogging torque and periodic load surge caused by non-Newtonian coating fluid shear thickening. The operating condition prediction unit removes the environmental mechanical background noise, including the 6th harmonic component, through differential operation, extracts the pure 12th harmonic dynamic load characteristics, and calculates the amplitude fluctuation rate of the harmonic current component. The operating condition prediction unit obtains the dynamic load parameters over 5 consecutive calculation cycles and determines the instantaneous slope by calculating the first derivative of the dynamic load parameters in the time domain. And according to the preset damping coefficient mapping table, the instantaneous slope The equivalent viscosity change rate of the coating fluid is converted to identify the viscoelastic evolution characteristics of the fluid in the pipeline. This damping coefficient mapping table is essentially a two-dimensional discrete data matrix solidified in the non-volatile memory inside the controller. Its vertical axis key value is the basic kinematic viscosity gradient of the coating fluid obtained by offline scanning with a standard rotating rheometer in a constant temperature water bath environment. The horizontal axis key value corresponds to the measured instantaneous slope of the current fed back when the pumping stand drives the same coating fluid. In each calculation iteration, the operating condition prediction unit uses the extracted current instantaneous slope as the address index to perform a binary search algorithm in the data matrix to lock the two nearest neighbor discrete calibration boundary points. Then, a first-order linear interpolation is used to calculate and approximate the accurate equivalent viscosity change rate value corresponding to the current slope. In order to determine the logical path in the calculation of the adjustment delay, the delay decoupling unit determines the real-time linear velocity of the current production line. With the length of the delivery pipeline The determined base time delay is superimposed with a viscoelastic compensation operator corrected for the equivalent viscosity change rate, thereby determining the adjustment time delay amount. The compensation synthesis unit introduces phase preprocessing into the original regulation command stream, causing the timing of the regulation action to be ahead of the flow deviation feedback time on the logic axis. The calibration command... Generate according to the following logical relationship: ,in, The calibration command for the current moment. This is the calibration command from the previous moment. Adjusted delay amount The corrected virtual phase bias is determined by the current sampling sequence number. Increase A lead time is obtained, The value is determined by adjusting the delay amount. With system sampling period The ratio is determined by rounding down. For proportional gain, This is the integral gain.

[0041] After receiving the calibration command, the closed-loop control unit determines the trigger state of the current action through its internal threshold discrimination module. The lower limit of the gradient dead zone is set to the standard deviation of the thermal noise level in the system current acquisition link. The upper limit of the coefficient of performance is dynamically calibrated based on the mechanical chatter amplitude of the pump drive source at rated speed. When the absolute value of the detected coating thickness deviation is less than 0.5%, the closed-loop control unit maintains the existing output frequency of the flow drive end; when the absolute value of the deviation is within the range of 0.5% to 1.5%, only proportional adjustment logic is executed to smooth out minor disturbances; when the deviation exceeds the dead zone upper limit of 1.5%, full-state phase offset compensation is activated. Finally, under the condition that the viscosity of the coating liquid changes by 25%, the consistency error of the coating thickness is reduced from 0.32μm to 0.09μm. The adjustment system adjusts the current at the drive end. The system performs spectral analysis on the characteristics of the material, converting its viscoelastic features into a phase compensation operator in the logic processing. This enables a physical mapping of the hysteresis effect in the transport of non-Newtonian fluids. This adjustment method, based on physical measurement and logical closed-loop, allows the system to adaptively perform real-time delay offsetting to address the dynamic drift of the material's rheological properties. While eliminating phase distortion between the adjustment command and the physical response, it also resolves the contradiction between adjustment accuracy and mechanical system lifespan during precision manufacturing through a dynamic dead-zone calibration procedure. In scenarios involving viscoelastic fluid transport loops with nonlinear damping characteristics, the delay decoupling unit adjusts the timing based on the pipe diameter of the transport pipeline. Pipeline length and the real-time flow rate determined by the closed-loop control unit. Establish a basic flow velocity mapping relationship, and use the reference time delay of material flow through the pipeline. The quotient with the average flow velocity is determined by introducing a viscoelastic correction factor to account for the additional momentum response hysteresis caused by the viscoelastic evolution characteristics. Compensation, adjustment of latency Follow the following logical relationship: ,in, It is a dimensionless viscoelastic correction factor, which is determined by the load prediction unit based on the instantaneous slope of the dynamic load parameters. Dynamically determined, based on the Ostwald-de Valley power-law fluid constitutive equation, the effective shear viscosity of a non-Newtonian fluid exhibits a nonlinear mapping relationship with the exponential power of the shear rate. The operating condition prediction unit calculates the instantaneous slope of the current sampling period. The ratio of the baseline slope to the standard slope is substituted into the power-law exponential transformation function pre-stored in the controller to calculate the dimensionless viscoelastic correction factor. Specific viscoelasticity correction factor The calculation formula is as follows: ,in, The slope of the dynamic stator current vector fluctuation obtained by actual measurement reflects the transient flow resistance step intensity of the coating liquid in the current pipe cross section; This means that, under the same pipeline length and baseline velocity, a constant reference slope constant is obtained by pre-calibrating the standard deionized water medium, which serves as a dimensionally unified base for smoothing steady-state fluctuations in the system. The representative determined the specific shear sensitivity coefficient of the target coating liquid through offline rotational rheometer testing and fitting, with the value range constrained between 0.15 and 0.35. This limits the nonlinear divergence of the fluid elastic hysteresis effect on the subsequent phase prediction width. This logarithmic mapping relationship is essentially an engineering dimensionality reduction mechanism for the exponential characteristics of the underlying power-law fluid. Since the actual shear stress of non-Newtonian fluids in pipelines exhibits exponential nonlinear divergence with flow rate, if the theoretical power-law equation is applied to high-frequency closed-loop regulation, even a small load ripple torque will cause an exponential overflow of the time delay compensation gain inside the controller. Therefore, this system introduces a logarithmic compression operator at the logic operation layer to map the slope ratio of the measured electrical parameters with power-law divergence characteristics to a linearly controllable phase adjustment range. This preserves the physical evolution trend of material shear thickening or thinning while ensuring the absolute numerical stability of the controller's underlying operation matrix. The compensation synthesis unit, based on the determined... The phase of the adjustment command is negatively offset so that the speed adjustment action of the flow drive end can offset the transmission and dissipation of fluid in the pipeline in the time domain, thereby maintaining the instantaneous fluctuation rate of the flow rate at the coating end below 0.5% under the condition of sudden change in material consistency.

[0042] Example 5: In the system initialization calibration scenario for a new easy-clean coating material, the flow drive unit drives a reference medium with determined rheological properties in a standard delivery loop. The load identification unit collects current response data of the pump drive source under different shear gradients. By extracting the amplitude characteristics of the 6th-order specific harmonic components, an offline calibration table is determined between the dynamic load parameters and the fluid viscoelastic characteristics to establish the logic operator benchmark required by the operating condition prediction unit in subsequent control. A preset flow disturbance signal is artificially injected in the calibration process to measure the basic time phase difference between the material's physical response and the adjustment command. This physical phase offset is used as the initial adjustment delay of the time delay decoupling unit. The quantitative basis for this process is that the parameter mapping generated in this process enables the logic layer to have initial perception accuracy for specific pipeline topologies.

[0043] When the system encounters physical impedance drift caused by minute deposits in the pipeline or drastic external temperature changes, the closed-loop control unit acquires the background value of the static electrical parameters of the pump drive source before the actual preparation command is issued. This background value is used to normalize the input signal of the load identification unit. During the first flow stabilization cycle at the start of the formal preparation process, the system compares the current load fluctuation slope deviation with the offline calibration table. The compensation synthesis unit then converts this deviation into an adaptive phase correction factor to compensate for and adjust the time delay in real time. In the case of computational errors under non-standard environments, when the measured dynamic load parameters remain constant within a continuous 500ms sampling window, the steady-state holding module locks the current phase pre-operator, so that the response curve of the logic adjustment loop is physically aligned with the changing trend of the fluid property state in the time domain.

[0044] Example 6: In the pre-deployment calibration scenario of the adjustment system for adapting to high-viscosity transparent easy-clean coatings, the load identification unit monitors the static current of the flow drive terminal under no-load conditions in an environment with a constant temperature of 25°C and an ambient humidity of 45%. The control unit injects an excitation signal with an amplitude of 10% of the rated frequency into the pump drive source. The flow sensor installed at the coating end captures the start time of material outflow to determine the time span from the issuance of the excitation signal to the change in the terminal flow rate. This time span is determined as the original adjustment delay of the system under this fluid condition. The load identification unit acquires 10 sets of time delay data points under different flow gradients by changing the output rotation speed of the flow drive end, and fits the discrete data points to generate information about the real-time linear velocity of the production line. The basic time delay function curve.

[0045] When the system encounters a viscoelastic coefficient shift due to batch replacement of the coating liquid, the adjustment system initiates an adaptive benchmark calibration procedure before entering the preparation process. The load identification unit extracts the 6th and 12th harmonic current amplitudes of the pump drive source when driving the standard test liquid under three sets of standard test liquid environments with viscosities of 800 mPa·s, 1200 mPa·s, and 1600 mPa·s, and records the instantaneous slope of the dynamic load parameter under the corresponding conditions. This allows for the construction of a linear mapping matrix between the equivalent viscosity change rate and the phase compensation operator. The correction value is determined according to the following formula: ,in, For phase compensation operators, The slope was measured on-site. To calibrate the baseline slope, The proportional conversion coefficient is used by the compensation synthesis unit to superimpose the fitted correction factor onto the original control command stream, which is the calibration command output by the closed-loop control unit. The phase compensation operator corrects the torque response phase of the drive mechanism based on the real-time drift of the material impedance. Unable to directly intervene in the underlying bus frequency modulation hardware, the system operates the base frequency in real time based on the flow-driven frequency converter, calculates the single-pulse duty cycle corresponding to the base frequency, and the compensation synthesis unit extracts the phase compensation operator. The physical proportionality coefficient of the complete electrical angle period, multiplied by the single-pulse duty cycle, is equivalently converted into an absolute time lead. The closed-loop control unit is based on the extracted time advance amount. The system proactively blocks the current frequency adjustment command on the main logic clock counting chain, forcing the underlying communication bus to refresh and issue the speed control word for the next adjustment cycle in advance. This speed command is not executed in isolation during the advance issuance of the communication layer. At the moment the bus data refresh is triggered, the system hardware driver synchronously releases the steady-state current limiting loop of the motor and injects a transient overshoot excitation voltage with an amplitude of 1.2 times the rated operating condition into the stator coil. This high-energy burst pulse in the electrical layer causes the motor to generate a steep mechanical torque peak. This peak torque acts on the rotor and is directly converted into a powerful hydraulic shock wave on the non-Newtonian fluid in the conveying pipe. The shock wave energy is used to actively cut off and dismantle the resistance of the stagnant layer on the inner wall of the pipe established by the viscoelasticity of the coating liquid. This energy overshoot mechanism, which is linked by the time advance of the logic layer to the electrical layer, reconstructs the momentum transfer of the fluid in the pipe from a physical perspective. It realizes the deterministic intervention of the advance control command on the physical evolution process of the physical fluid. With a speed fluctuation frequency of 2Hz on the production line, the coating amount fluctuation is controlled within 1.2%.

[0046] In the field integration scenario of a distributed logic control system, the closed-loop control unit is connected to the frequency converter drive mechanism at the flow drive end via a bus interface, and receives calibration commands output by the compensation synthesis unit. This is then converted into the operating frequency of the variable frequency drive mechanism. When the flow drive detects a nonlinear offset in the output torque due to increased material yield stress, the system neutralizes the command phase distortion at the logic layer by adjusting the injection width of the phase lead component. This neutralization process is accomplished by superimposing an advance compensation amount in the frequency adjustment loop. The amplitude of this compensation amount is related to the calibration command. The rate of change is proportional to the material's physical state response time. This process aligns the triggering time of the adjustment action with the response time of the material's physical state on the logic axis, so that the thickness deviation of the coating device during the high-speed operation switching phase is maintained within 0.05μm.

[0047] The embodiments of this application have been described above with reference to the accompanying drawings. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. This application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit of this application and the scope of protection of this invention, and all of these forms are within the protection scope of this application.

Claims

1. A logic control system for an easy-clean coating preparation process, characterized in that, The system includes: The load identification unit, which is connected to the flow drive end, is used to monitor the electrical parameters of the pump drive source and extract dynamic load parameters that characterize the electromagnetic torque pulsation rate of the pump drive source, so as to identify the transient electromagnetic characteristic changes generated by the flow drive end when driving non-Newtonian fluid. The working condition prediction unit, which is connected to the load identification unit, is used to determine the viscoelastic evolution characteristics of the coating liquid under the current shear conditions by using the instantaneous slope of the dynamic load parameters in the time domain, so as to capture the damping characteristic shift trend caused by the consistency fluctuation of the coating liquid. The time delay decoupling unit, which is connected to the working condition prediction unit, is used to calculate the adjustment time delay between the command issuance time of the flow drive end and the physical response state of the coating liquid based on the preset fluid dynamics model and the viscoelastic evolution characteristics, so as to quantify the momentum lag of the fluid in the delivery pipeline. The compensation synthesis unit, which is connected to the time delay decoupling unit, is used to superimpose phase cancellation components that are opposite to the adjustment time delay in the original adjustment command stream to synthesize a calibration command with time delay offset characteristics, so that the timing of the adjustment action leads the physical deviation feedback time on the logic axis. The closed-loop control unit, connected to the compensation synthesis unit, is used to adjust the output frequency of the flow drive in real time according to the calibration command, so as to neutralize the command phase distortion induced by the adjustment delay and maintain the consistency of the coating thickness.

2. The logic control system for an easy-clean coating preparation process according to claim 1, characterized in that, The load identification unit is used to perform spectral decomposition on the monitored electrical parameters to extract harmonic current components of a specific order, and correct the confidence level of the dynamic load parameters based on the amplitude fluctuation rate of the harmonic current components, thereby removing high-frequency noise disturbances in electrical parameters introduced by environmental mechanical vibration.

3. The logic control system for an easy-clean coating preparation process according to claim 1, characterized in that, The compensation synthesis unit includes a time axis calibration module, which is used to acquire the real-time linear velocity of the preparation production line and linearly scale the injection time of the phase cancellation component according to the ratio of the real-time linear velocity to the physical distance from the sensor to the coating point, so as to achieve phase alignment under varying operating conditions.

4. The logic control system for an easy-clean coating preparation process according to claim 1, characterized in that, The closed-loop control unit includes a steady-state holding module, which stops logical updates to the calibration command and locks the current operating frequency of the flow drive when the acquired coating thickness deviation is within the gradient dead zone range of 0.5% to 1.5%, in order to suppress mechanical chatter of the pump drive source.

5. The logic control system for an easy-clean coating preparation process according to claim 1, characterized in that, The load identification unit is used to collect the steady-state average current of the pump drive source under the reference operating condition of constant frequency at the flow drive end and use it as a static reference. Then, the static reference is used to normalize the electrical parameters monitored in real time to extract the transient load component.

6. The logic control system for an easy-clean coating preparation process according to claim 1, characterized in that, The system also includes a limiting protection unit, which monitors the output amplitude of the calibration command and, when the output amplitude exceeds the preset safety envelope, saturates and cuts off the calibration command according to physical limits to prevent the closed-loop system from running out of control due to prediction deviation.

7. The logic control system for an easy-clean coating preparation process according to claim 1, characterized in that, The operating condition prediction unit is used to query the preset rheological property mapping library, convert the dynamic load parameters into physical scalar indices that characterize the changes in surface tension and consistency of the coating liquid, and use the physical scalar indices as input weight parameters for the compensation synthesis unit to calculate the phase cancellation component.

8. The logic control system for an easy-clean coating preparation process according to claim 1, characterized in that, The compensation synthesis unit is used to continuously record the historical fluctuation trajectory of the adjustment time delay, and when the historical fluctuation trajectory exhibits periodic resonance characteristics, it reduces the proportional gain coefficient of the phase cancellation component to eliminate the risk of pipeline system resonance caused by the viscoelasticity of non-Newtonian fluid.

9. The logic control system for an easy-clean coating preparation process according to claim 1, characterized in that, The system also includes a self-diagnostic unit, which is used to calculate the time-domain residual between the expected physical state corresponding to the calibration command and the actual response state of the coating liquid, and to correct the mapping accuracy of the viscoelastic evolution characteristics in the working condition prediction unit online based on the time-domain residual.

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